Separable multi-member composite cable

ABSTRACT

Discussed herein are multi-member cables which are comprised of two or more components (including component cables and non-cable components) held together by at least one adhesive element placed between the components, and methods for manufacturing such cables. Multi-member cables which are compromised of jacketed cables whose jackets are adhered together without the use of an adhesive element, such as by co-forming the jackets, and methods for manufacturing such cables are also discussed. Generally, the components will be separated from the multi-member cable by an installer, although other methods may also be used.

BACKGROUND

1. Field of the Invention

This disclosure relates to the field of cables, particularly tomulti-member composite cables where components are combined together ina single separable cable construct.

2. Description of the Related Art

In the modern world, cables are everywhere. They are used to transmitnumerous signals between individual electronic components that can rangefrom the very basic building blocks of electrical systems to the mostcutting-edge consumer and commercial devices. As the world becomes more“wired” there is a growing need for the cables that carry signals to bemore readily available and easier to install in both new and existinglocations.

This is particularly true for cables used inside structures such ashomes, other residences, or commercial establishments. Many of thesestructures do not have the necessary infrastructure to handle all themodern communication requirements. For instance, houses built many yearsago generally do not have internal cabling for a local area network(LAN), and may or may not have broadband cable TV or modern phone linesinstalled. Further as the so-called “smart house” concept becomes morepopular, there is a need for even more wiring that is not yet present inhomes being built. In particular, many of the smart house applicationsrequire that multiple devices in a plurality of different locations beable to hook up to both internal networks and data connections, as wellas external data lines and power.

Putting these types of cabling in older structures generally requiresretrofitting and rewiring. In particular, the cables need to beinstalled through walls which are already in place. This can be a timeconsuming and physically difficult procedure as generally the residentand/or owner of the structure does not want walls, floors or otherportions of the structure damaged to install the new cabling. To be ableto do this, it is therefore desirable to have a single cable constructthat allows for simultaneous installation of all the desired cablesthrough the walls. In this way when the cable installer gets one of thecables to its predetermined termination point, the other cables (whichare usually provided to a nearby termination point to be used by similardevices) are also already nearby.

The installation of this type of multi-member composite cable intoalready existing structures requires the installer to be able tomaneuver the cable where it needs to go within the structure. Inparticular, when a cable is installed in a new structure the cable oftendoes not need to be easy to bend or to turn as the cable can be bent asit is being installed. When installing new cable in an existingstructure, a cable will often need to be flexible so as to be able toturn and will need to be “steerable” so as to be more easily installedthrough existing walls.

Even when cables are being installed in a new structure where theinstaller has much more access, there are significant advantages tohaving cables that can be installed together. In particular, the cableswill usually terminate at points fairly close together as often a singledevice will use multiple hookups (for instance, a computer willgenerally need cables to supply power, a phone line, a LAIN line, andpossibly a broadband TV line). Further, as devices become moreinterconnected, even specialized devices are beginning to demandadditional hookups (for instance a console arcade system and associatedTV may require multiple hookups to different connections (such as, butnot limited to, audio, control, telephone, power, and broadband cable TVand also LAIN or other internal data hookups)). Even when devices onlyrequire a single hookup, there is generally a single point where anexternal hookup connects to the structure. Depending on the size of thestructure, even if hookups are distributed in a room or in multiplerooms, having them go from the single input to the room or roomstogether can be highly beneficial. Traditionally, each type of cable hasbeen separate, therefore a cable installer would need to install aseparate cable for each location.

The use of separate cables required the cable installer to carrymultiple reels of different cables, and to repeatedly install thecables. Further, it required the cable installer to perform the sameactions multiple times as they would install one cable and then installanother cable in the same position. This increases the total amount oftime it takes to wire a structure and is particularly problematic if theinstallation has points of particular difficulty as each additionalcable may dramatically increase the total number of steps needed to getit installed correctly. For instance, if the installer needed to threada cable through a small hole a significant distance away, the amount oftime it takes for the installer to do it successfully once is generallysignificantly less than the amount of time it takes for the installer toperform the same action 5 or 6 times. This is particularly true if thealready installed cable gets in the way of installing later cable.

To try and make the installer's job easier, there have been created sometypes of multi-member cables, where multiple different types of cable,such as coaxial cables and twisted pair cables are combined into asingle multi-member cable by enclosing all the individual componentcables in a single overall jacket which retains them all together. Thisarrangement allows the installation of a single multi-member cablethrough the structure. Once the multi-member cable is in the generallocation where an individual component cable is to be installed, thejacket can then be stripped and the individual components separated sothat they can be installed to nearby terminators or panels.

While these overall jacketed cables help to solve the underlying problemof separately installing multiple cables, they also create new problems.Firstly, stripping the overall jacket is generally a fairly tediousoperation and can require specialized tools (due to the large size andsometimes convoluted shape of the composite cable). Sometimes even withthese tools, the cables can slip and move relative to each other insidethe jacket causing further problems. Further, because removing the outerjacket involves cutting into the composite cable, a component cable canbe damaged by this activity as cutting into the overall jacket caninadvertently lead to cutting into an underlying component cable. Thismay result in an internal component cable being unusable and the wholecomposite cable having to be replaced and reinstalled which is both timeconsuming and wasteful. Further, the outer overall jacket generally addsstiffness and increases the overall diameter of the cable. This canoften make the cable difficult to maneuver into tight points or aroundcorners and adds cost to the resultant product.

An additional problem with the overall jacketed composite cable is thatthe separation of the composite cable is an all or nothing procedure.Therefore, if the cable installer wants to install a single componentcable from the composite at one point, and the remaining components at apoint twenty feet away, the cable installer is generally forced to striptwenty feet of the overall jacket from the composite cable so as toaccess the internal component(s) needed, and then install the remainingtwenty feet without the benefit of the overall jacket. This oftendefeats any benefit that would have been obtained from using the overalljacketed composite cable in the first place, and this premature forcedseparation can make installing the remaining components even moredifficult as the component cables have to be installed simultaneously,while each moving and interacting separately.

Another type of multi-member cable is what is referred to as a binderedcable. This is generally of similar structure to an overall jacketedcable in that the component cables are held together by an external“wrap” or binder which encircles them. In a bindered cable, the wrap isnot a jacket but is a narrow binding material that encircles thecomponent cables. Generally these binders are ribbons of polyester ornylon wrapped in either concentric rings or a helical pattern about thecomponent cables. Bindered cables suffer from many of the same problemsas the overall jacketed cable and further can more easily be snagged onobstructions while the cable is being installed. Further, the binderedcable will often not meet industry cable performance specificationsleading to multi-member cables of less than desirable quality.

SUMMARY

Because of these and other previously unknown problems in the art,disclosed herein are multi-member composite cables (or multi-membercables or composite cables as the terms are used interchangeably) whichare comprised of two or more components, such as component cables and/ornon-cable components, held together with at least one section of anadhesive element placed between the components, and methods formanufacturing such cables.

Also disclosed are multi-member composite cables which are comprised ofjacketed component cables whose jackets are adhered together without theuse of an adhesive element, such as by co-forming the jackets, andassociated methods. These cables are all generally intended to be usedby an installer who will install the multi-member cable to apredetermined point, where he or she will then separate at least one ofthe component cables and then install the separated component cable(s)to different points.

Described herein is an embodiment of a multi-member cable comprising: anadhesive element, a first component cable, and a second component cable,wherein the adhesive element is placed between the first component cableand the second component cable such that the first component cable isadhered to the adhesive element and the second component cable is alsoadhered to the adhesive element. The component cables may be jacketedand the adherence may be to the jackets. Any of the component cables maybe voice or data cables, broadband coaxial cables, other coaxial cables,or optical fiber cables. The multi-member cable may also be twisted intoa helix.

In an embodiment the adhesive element may comprise plastic such as, butnot limited to, Polyvinyl chloride (PVC) and/or may adhere with aboutthree pounds of force.

In an embodiment, the multi-member cable may further comprise a thirdcomponent cable and/or a fourth component cable and/or a fifth componentcable. The adhesive element may also be adhered to the third componentcable, the fourth component cable, and/or the fifth component cable. Inanother embodiment, the multi-member cable may include a second adhesiveelement, the second adhesive element being adhered to the thirdcomponent cable, the fourth component cable, and/or the fifth componentcable. Each of the component cables may be jacketed and the adherencemay be to the jacket.

In another embodiment, the multi-member cable may include a non-cablecomponent, such as, but not limited to, a tube to which the adhesiveelement is also adhered.

In another embodiment, there is described a multi-member cablecomprising a first component cable, the first component cable having ajacket as its outer surface; a second component cable, the secondcomponent cable having a jacket as its outer surface; a third componentcable, the third component cable having a jacket as its outer surface;and a fourth component cable, the fourth component cable having a jacketas its outer surface; wherein at least two of the first component cablejacket, the second component cable jacket, the third component cablejacket, and the fourth component cable jacket are co-formed. The cablemay also include a fifth component cable whose jacket is co-formed withat least one of the above jackets and/or a non-cable component which maycomprise a tube which is co-formed with at least one of the componentcable jackets.

In another embodiment there may be further included an adhesive elementadhered to any selected component cable jacket and at least one othercomponent cable jacket. In another embodiment, the multi-member cablemay include a non-cable component which in turn may comprise a tubewhich is co-formed with at least one of said component cable jackets.

In another embodiment, there is described a method of installing cablecomprising: providing a multi-member cable including at least twocomponent cables, installing the multi-member cable into a location,grasping a terminating end of the multi-member cable, and separating atleast one of the component cables from at least one other of thecomponent cables by breaking a bond between the component cables. Thebond may be formed by an adhesive element adhered to both the componentcables or by co-forming both the component cables.

In yet another embodiment, there is described a machine for constructinga multi-member cable comprising: a crosshead, the crosshead aligning atleast two component cables relative to each other; an extrusion die, theextrusion die extruding an adhesive element, such as, but not limitedto, a plastic such as polyvinyl chloride (PVC) between the alignedcomponent cables; and a closing device, the closing device forming thecomponent cables into the adhesive element so that the adhesive elementadheres to the component cables.

In still another embodiment, there is described a method forconstructing a multi-member cable comprising: providing at least twopreviously assembled component cables, placing the component cables inproximity to each other, providing an adhesive element between thecomponent cables, passing the component cables through a forming devicewhich presses the component cables into the adhesive element; andsolidifying the adhesive element.

In still another embodiment, there is described a method forconstructing a multi-member cable comprising: providing at least fourcomponent cables, jacketing the component cables at a substantiallysimultaneous time, such as by passing the component cables through asingular extrusion die with multiple exit points, placing the cables inproximity to each other, passing the component cables through a formingdevice which causes the jacketing on the component cables to co-form,and solidifying the jacketing, such as by cooling the jacketing.

In still another embodiment, there is described a multi-member cablecomprising: an adhesive element, a component cable, and a non-cablecomponent, wherein the adhesive element is placed between the componentcable and the non-cable component such that the component cable isadhered to the adhesive element and the non-cable component is adheredto the adhesive element.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 depicts three embodiments (FIGS. 1A, 1B, and 1C) of multi-membercomposite cables utilizing an adhesive element construction and havingfour component cables.

FIG. 2 provides two different views (FIGS. 2A and 2B) of anotherembodiment of a multi-member composite cable utilizing an adhesiveelement construction and having five component cables.

FIG. 3 depicts another embodiment of a multi-member cable without anadhesive element and having four jacketed component cables.

FIG. 4 shows multiple views of an embodiment of a machine for forming amulti-member cable by injecting an adhesive element between thecomponents as shown in FIGS. 1 and 2. FIGS. 4A and 4B show general viewsof the machine while FIG. 4C provides a magnified view of the crosshead,extrusion die, and closing die.

FIG. 5 provides an embodiment of a device for forming a multi-membercable such as that shown in FIG. 3.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT(S)

Although the cables and methods described below are discussed primarilyin terms of their application to the installation of multi-member cablesin structures, multi-member cables can be used anywhere that componentcable(s) making up the composite are desired. In particular, thecomposite cables can essentially be used anywhere where at least one ofthe component cables making up the composite cable is desired. Further,while the multi-member composite cables discussed herein are primarilymade from coaxial cables and twisted pair voice or data cables (orCATEGORY cables), a multi-member cable could be manufactured from anycombination of component cables such as, but not limited to, powercables, data cables, voice cables, voice or data cables, control cables,low voltage power limited cables, paired cables, twisted pair cables,multi-conductor cables, multi-pair cables, armored cables, audio cables,fiber optic cables, coaxial cables, triaxial cables, twinaxial cables,or any combination thereof. Further, a composite multi-member cablecould also include strength or load-bearing members, fillers, tubes,hoses, liquid absorption products, or other non-cable components whichare not cables, but are desired to be included in the compositemulti-member cable. Further, the component cables which make up themulti-member cable will generally be insulated or “jacketed” asunderstood by one of ordinary skill in the art. That is, an uninsulatedconductor or a cable with uninsulated conductor(s) as its outer surfacewill generally not be used as that component will typically be encasedin an insulative cover or “jacket.” One of skill in the art, however,would understand that alternative embodiments could utilize bareconductor(s), strength or load-bearing members, surface conductors,and/or cables of any type or any type of non-cable component therein.

For purposes of clarification, certain terms will be used herein togenerally refer to particular things. Firstly, the term cable will beused to generally represent any cable, wire, cord, conductor, opticalfiber, or similar object that is generally used to transport electricalimpulses or signals, light, or other signals regardless of type. Anycable can comprise one or more component cables and may also include anynumber of non-cable components therewith. The term multi-membercomposite cable (or multi-member cable or composite cable as the termsare used interchangeably throughout this disclosure) will generallyrefer to the subset of cables, formed of at least two component cables.A multi-member cable may also include any number of non-cable componentstherewith. That is, a multi-member cable is a composite cable formedfrom other cables, called component cables and/or non-cable components(either of these is occasionally referred to simply as a “component”). Amulti-member composite cable can therefore comprise two or more cables,which can each in turn comprise any number of cables and so on. Forexample, two multi-member composite cables can be formed together intoanother multi-member composite cable. These definitions and any otherswithin this disclosure are intended for general clarification only andshould in no way be used to limit the meaning of any term herein asunderstood by one of ordinary skill in the art.

FIGS. 1 and 2 depict multiple Embodiments of multi-member cables inaccordance with the present invention. In FIG. 1 there are depictedmultiple embodiments of multi-member cables having four component cableswhile in FIG. 2 there is an embodiment of a multi-member cable with fivecomponent cables. In the embodiments of FIGS. 1 and 2, the componentcables generally comprise jacketed coaxial cables (10), voice or datacables (20), audio cables (30), optical fiber cables (40) twinaxialcables (50), or combinations of these types of component cables, but anyother components may be used, including alternative component cablesand/or non-cable components. In particular, FIG. 1A shows a multi-membercable (112) including two voice or data cables (20) and two broadbandcoaxial cables (10). FIG. 1B shows a multi-member cable (122) includingfour voice or data cables (20). FIG. 1C shows a multi-member cable (153)including two voice or data cables (20), a twinaxial cable (50) and anaudio cable (30). FIGS. 2A and 2B show a multi-member cable (241)including an optical fiber cable (40), two voice or data cables (20),and two broadband coaxial cables (10). The combinations shown are in noway intended to be exhaustive of the multi-member cables which can beformed using these component cables or even exhaustive of the types ofcomponent cables or non-cable components which may be used in anyparticular multi-member composite cable.

In each of the depicted embodiments, the components are held together ina predetermined arrangement using at least one adhesive element (101),(311), and/or (313) regardless of which types of component cable(s) ornon-cable components are used. In the simplest case, there is a singularadhesive element (101) which connects all the components (as in FIG.1B). However, in another embodiment, there can be multiple adhesiveelements (such as adhesive elements (311) and (313)) used in a singlecable. All of these adhesive elements (101), (311), and (313) aregenerally comprised of a material that has a certain minimum adherenceto the jackets, or other outer surfaces, of the component cables and toany non-cable components. As shown in the embodiments of FIG. 1, theadhesive elements will generally be placed inside the area defined bythe components being therefore generally between them. The adhesiveelements will generally not be on the outer surfaces of the compositecable, but enclosed within the composite cable. For the purpose of thisdisclosure, any reference to adhesive element (101) could also refer toany other adhesive element (311) and/or (313) and vice-versa as all theadhesive elements (101), (311), and (313) can be of essentially the samematerial construction. Their placement in the resultant multi-membercable is the only difference between them. Further, any reference to acomponent cable could just as easily refer to a non-cable component.

Use of a multi-member cable such as those shown in FIGS. 1 and 9 willgenerally occur as follows. An installer will take the multi-membercable and install it in the desired location inside a structure and tothe general termination points of the components. The installer willthen grasp the terminating end of the multi-member cable and separate atleast one component cable from the multi-member cable (as partiallyshown in FIG. 1B) by exercising a force to separate the componentcable(s) from the adhesive affect of the adhesive element or adhesiveproperties of the jackets (as discussed below in conjunction with FIG.3). The installer will then direct the component cable(s) to the desireddestination point and attach an appropriate terminator. The installerwill then repeat the separating, directing and termination steps untilall the component cables are correctly installed to their destinationpoints.

An adhesive element may comprise any of a plurality of materials aswould be known to one of ordinary skill in the art. The only requirementof any adhesive element is that it adhere to another substance. It ispreferable that the material of an adhesive element bond with thematerial of the component cable(s) (or other components) with sufficientstrength to prevent unintended separation when the multi-member cable iscoiled or otherwise manipulated. At the same time, the bond is alsopreferably sufficiently weak to be readily hand-separable or separablethrough the use of hand tools without danger of damage to the componentcable(s) or other non-cable component(s). In particular, if an adhesiveelement bonds too strongly, a component cable jacket may be torn, or anon-cable component may be damaged when an installer attempts toseparate the components. Generally, the adhesive element will be appliedto a particular surface of the component interior to the resultingcomposite cable as shown in the FIGS. One of ordinary skill in the artwould understand that stronger or weaker adhesive forces withcorresponding changes in adhesive element surface area would clearly beequivalent. It has been found that an adhesive element requiring aboutthree pounds of force to separate from a component is preferable to meetthe above qualifications for ease of use and sufficient strength.

It is further preferable, but by no means required, that the adhesiveelement (101) have flame retardancy qualities sufficient to meetaccepted industry standards and/or guidelines when applicable. It isalso preferable that the material used have a relatively quick drying(solidifying) time so that it can be solidified in the normal-course ofmanufacture. Otherwise the multi-member cable manufacture may requireundue time constraints to build, or may become damaged if it is spooledor stored before the adhesive element (101) is completely solidified.Along with this, it is also preferable that the adhesive element (101)remain in its solidified state under normal conditions in which thecomposite cable will be used or stored to prevent the composite cablefrom separating or becoming damaged after manufacture.

In an embodiment, the adhesive element (101) may comprise a formulatedchemical adhesive or glue as is known to those of ordinary skill in theart. These can include, but are not limited to, glues, caulks, or otheradhesive substances. Generally these substances will begin in apartially liquid (e.g. gel or paste), liquid, or otherwise malleable oralterable form and will solidify through chemical interaction, heating,drying (evaporation of an ingredient), or other process or processes toan at least partially rigid steady state. It is preferred that the rigidstate still maintain some flexibility. Those of ordinary skill in theart would be able to readily identify numerous such materials.

In another embodiment, the adhesive element may be a more generalmaterial which can be placed in a liquid, molten, or partially solidstate through the application of heat and/or pressure, where it becomessticky and then solidifies as it is allowed to cool to room temperature.Once at room temperature, the material will preferably solidify in amanner that will bind it to neighboring substances that it had beenplaced in contact with. In some embodiments, materials such as, but notlimited to, plastics, biomatters, vinyl, glass, rubbers and even somemetals may be used. Plastics, and particularly polyvinyl chlorides(PVCs), are most preferable because they generally solidify to astructure that is still quite flexible and are not brittle or overlyrigid. PVC is most preferable because it generally meets acceptedindustry flame retardancy standards and guidelines, and will generallyadhere to materials used in cable jackets with about three pounds offorce. One of ordinary skill in the art would also recognize that anycombination of materials could be used as different adhesive elements(311)/(313) in the same cable or combined together as a single adhesiveelement (101).

The embodiments of FIGS. 1C and 2 provide that the cables need not besymmetrically arranged. Further, in some of the depicted embodiments,the adhesive element (101) is replaced by other adhesive elements (313)and/or (311) separated from each other by a separation (such asseparation (360)) which places air space between the components. Theadhesive elements (311) and (313) are each in contact with only some ofthe component cables and may bind a subset of the component cablestogether. In an embodiment, this type of arrangement is used because itcan allow for easier placement of the adhesive element within the cablearrangement. In particular, there essentially may be multiple points ofbinding the cables together which effectively forms subsets of cable.This can mean that cables can be combined into multi-member cables, withthose multi-member cables then combined together to form largermulti-member cables without having to use excessive adhesive elements orform the final multi-member cable in a singular step.

A further advantage of the use of subsets is that certain groups ofcables can be sub-bundled. For example, a single multi-member cablecould include two of each type of cable (as shown in multi-member cable(12) in FIG. 1A). The installer could install the multi-member cable(112) into the structure where both subsets are to be installed, once aparticular point where the cables were to be split was reached, theinstaller could separate the two subsets using adhesive element (311) tohold one subset together and adhesive element (313) to hold the other.Therefore, each adhesive element corresponds to a single installationsubset and allows placement of the subset, without separating the twocomponent cables for the particular subset (one broadband coaxial andone voice or data) from each other. The installer could then installeach subset as a single cable even when the subsets were directed todifferent locations. The benefit of such an arrangement should bereadily apparent as often cable subsets go to similar locations even ifthe total multi-member composite cable is split and maintaining theconnection of the subsets preserves some of the benefits of forming theoriginal multi-member cable.

One of ordinary skill in the art would understand that exact placementof the adhesive element within any given multi-member cable requires asignificant number of design choices including the intended use of theresultant multi-member cable. In an embodiment, the adhesive element canbe continuous (e.g. unbroken) so as to form a constant area ofconnection down the entire length of the cable for the various adhesiveelement portions (or single adhesive element). In an alternativeembodiment, an adhesive element can be intermittent forming smallerpatches or “blobs” of adhesive element through the length of the cable.This arrangement may serve to make the resultant cable more flexible orcould be used to produce the cable at a lower cost, or to allow theportions of the adhesive element where the cables are separated to beeasily removed and discarded when the cable is installed.

In another embodiment, the adhesive element could have a predefinedshape which it may or may not maintain. For instance, the adhesiveelement may generally be arranged to have a particular polygon in crosssection. This may be used to maintain the relationship of the componentcables to one another. For instance, the polygon could be an “X” shapeto maintain physical separation between four component cables from eachother. In still another embodiment, the shape could be predeterminedwhen the adhesive element is formed, but it could be deformed by thecomponents.

While in the embodiments of FIGS. 1 and 2 only an instant or smallportion of any multi-member cable has been shown, one of ordinary skillin the art would understand that the multi-member cable may includevariations over its length. As discussed above, this variation may bethe existence or non-existence of the adhesive element at a particularpoint along the length. In another embodiment, the multi-member cablemay be formed with component cables which twist or bend over theirlength. For instance, each component cable may trace a helical pathabout the multi-member cable as shown in FIG. 2B. It is preferred thatthe multi-member cable have a helical twist because it provides forstrain relief when the multi-member cable is coiled or otherwise bentand may also provide for various aesthetic benefits to the resultantcable.

FIG. 3 provides for an alternative embodiment of a multi-member cable.In FIG. 3 there is no adhesive element used in multi-member cable (201).Instead the outer jackets (221), (223), (225) and (227) of the componentcables (211), (213), (215) and (217) are heat formed together or“co-formed”. In particular, the jacket material of most cables issuitable for use as an adhesive element. In the embodiment of FIG. 3,instead of adding the adhesive element, the jacket material is melted(heat treated) to soften it. The cables may then be formed together andwhile they are so interacting, create a bond between the cablesgenerally internal to the resulting composite cable. This can be thoughtof as essentially performing the same activity as in the embodiments ofFIGS. 1 and 2, however, the adhesive element is essentially formed bymelting or otherwise altering the jackets of the component cables; it isnot separately added. Since the material of the jacket may be used as anadhesive element, the result in the embodiment of FIG. 3 is essentiallythe same as the result in FIG. 1, simply with generally less of thematerial used. One of ordinary skill in the art would recognize thatco-forming could also be used to combine component cables with othernon-cable components. For instance, the component cable jacket could beco-formed with a tube formed of jacket material which later hasstructures (such as optical fibers) placed therethrough. In otherembodiments still other non-cable components could be used.

The embodiments of FIGS. 1 and 2 are generally preferred to theembodiment of FIG. 3. The embodiments of FIGS. 1 and 9 will generallydecrease the possibility of “gaps” or spaces being formed in thecomponent cable jackets during the connection process. Further, theadhesive element can have different properties than the jacket ifseparately chosen. In FIG. 3, there is also the possibility of thecomponent cable core properties being chanced through the heat formingprocess. In particular, by melting the jacket surrounding the componentcable, the cables, wires, and/or shields internal to that componentcable may move relative to the jacket. In particular, in certain typesof cable it is highly desirable that the core be centered within thejacket. If the jacket is altered (such as by melting, pressing, or otherprocess) the core may no longer be centered which could decrease theelectrical performance of the cable. The co-forming can also result in abond which is of equivalent strength to the jacket itself (for instancewhen both cables use the same jacketing material). This bond isessentially just reforming the shape of the jacket to include bothcables. When the cables are separated it is therefore likely that thecables will not separate in as clearly defined a location as when adifferent adhesive element is placed between the component cables. Inparticular, the jacket may tear. If the joint is the point that is theweakest, this may be a suitable design, but if the design leads toweaknesses elsewhere in the jacket, the attempt to separate the cablesmay damage them.

FIGS. 4A. 4B, and 4C provide different views of a machine which may beused to manufacture a multi-member cable. In particular, this machine isdesigned to manufacture multi-member cable with an adhesive element suchas the embodiments of FIGS. 1 and/or 2. The system (450) generallyincludes a crosshead (451) with an associated extrusion die (453).Generally the crosshead (451) and extrusion die (453) will be integratedand the combination mounted between the cabling guide plate (461) andthe cabling machine (cabler (not shown)). The cabling guide plate (461)and cabler (not shown) are of the type generally known to those ofordinary skill in the art. The crosshead (451) generally is designed toensure that cables (491), (493), (495), and (497) or any non-cablecomponents are properly aligned relative to each other as the componentsapproach the extrusion die (453). The extrusion die (453) is designed toextrude a stream or other source of adhesive material. In the preferredembodiment the crosshead (451) is actually part of an extruder forplastics that also include various associated apparatus such as a hopperfor storing raw plastic pellets, a feeder for feeding the raw plasticinto the system, and a device for heating the plastic to the moltenstate that is then extruded. In an alternative embodiment, any type ofadhesive may be extruded through extrusion die (453) and the extrusiondie (453) can be thought of as being a tip to a glue container orsimilar device. One of ordinary skill in the art would understand thatthe shape of the extrusion die (453) will determine the shape of theadhesive element when it is extruded. While some adhesives will notmaintain this shape (as they are too runny or thin), in someembodiments, including those where PVC plastic is used, the adhesiveelement can maintain the shape it is extruded in when not exposed toexternal forces.

It is generally preferred that a PVC adhesive element be extruded andthen compressed by the cables (491), (493), (495), and (497) into ashape which fills the void between the cables as shown in FIG. 1B. Thiscompression is accomplished by closing die (471). Closing die (471) isgenerally a rigid piece of material with an opening (473) that isdesigned to constrain the components passing through it into aparticular arrangement. In the depicted embodiment, the shape isgenerally constrained to align the cables (491), (493), (495), and (497)as shown in FIG. 1. The opening (473) may include, but is not limitedto, rollers, ball bearings, or other surfaces (476) which are designedto apply pressure to the multi-member composite cables as they passthrough. Generally, the opening (473) will be sized so as to require thecables (491), (493), (495), and (497) to pass therethrough in closeproximity to each other. In particular, it is usually designed so thateach of the component cables will be brought into contact with theadhesive element that has been extruded between them. To produce cableswith more than one adhesive element section, additional dies can beincluded in tandem or in series with extrusion die (453). Alternatively,independent devices could be used to form the subsets of multi-membercables, which are then combined using a similar process to thatdescribed.

In a preferred embodiment the machine operates generally as follows.Component cables or other non-cable components that have been previouslyproduced are fed from spools into the cabling guide plate (461) whichaligns them and makes sure they are positioned correctly relative toeach other. The components are then routed from the guide plate (461)into the extrusion crosshead (451) in a generally converging pattern.The extrusion crosshead (451) further serves to align the componentswith the extruded adhesive element (101) that is extruded inside theconverging arrangement of components. Generally, this adhesive element(101) will be molten PVC and will be extruded from the extrusion die(453). The components and extruded adhesive element are then fed into aclosing die (471) where the components are brought into contact with theadhesive element (101) (and possibly each other), in a manner whichcreates surface contact between the adhesive element (101) and thecomponents. Further, the closing die (471) generally imparts aparticular shape to the arrangement of component cables (491), (493),(495), and (497) and/or other components as they pass therethrough. Thecomponents are generally pulled through the system by a cabler (notshown) which essentially through the application of tension on one endof the cables (491), (493), (495), and (497) pulls the cables from theirspools through the described apparatus. In the preferred embodiment, thecabler provides a twist or helix structure to the resultant multi-membercable. This twist is shown in FIG. 2B. This twist or helix allows forstrain relief on the components and/or resulting multi-member compositecable. In alternative embodiments such a twist or helix is notnecessary.

Depending on the type of adhesive element used, the multi-member cablemay be fed into a solidifying apparatus after leaving the closing die(471). As would be understood by one of skill in the art, a commonmethod for cooling extruded plastic is the use of a water trough (notshown) through which the warm plastic passes, the water cooling theplastic through surface contact. This type of cooling apparatus may beused to cool extruded plastic forming the adhesive element therein byhaving the multi-member cable pulled through such a cooling apparatus.The multi-member cable, once cool, can then be spooled or packaged.

FIG. 5 depicts another embodiment of some of the components of anassembly machine. Machine utilizing these structures would generally beused to manufacture a multi-member cable such as that shown in FIG. 3where no separate adhesive element is used. As shown in FIG. 5, theindividual cables are jacketed using the standard extrusion process asis known to those of ordinary skill in the art. However, in this case,the component cables (591), (593), (595), and (597) will generally notbe cooled, completed, and spooled. Instead the four cables (591), (593),(595), and (597) will generally be simultaneously jacketed using asingle extrusion die (511). This extrusion die (511) has multiple exitpoints (521), (523), (525), and (527) each of which provides for theconstruction of cables (591), (593), (595), and (597) to be producedsimultaneously. Extrusion die (511) may also form non-cable componentsto be included in the resulting multi-member composite cable. Theextruded cables (591), (593), (595), and (597) are then formed togetheras is shown and they pass through a forming device (566). This formingdevice (566) may generally be of similar construction to closing die(461) so that the cables are generally formed together. In thisembodiment, however, the forming device (566) will generally includemoving surfaces adjacent the opening (570) to prevent the jackets ofcables (591), (593), (595) and (597) from sticking thereto as thejackets (which were extruded above) are generally still partially molten(“tacky”). The components are pushed together by forming device (566)such that the material of their jackets is placed in contact. As thismaterial is still molten, it merges making the jackets co-form betweenthe component cables. It is preferable that this be accomplished in amanner such that the forming device (566) does not distort the shape ofthe individual component cables (591), (593), (595), and/or (597). Theplacement and shape of the components of forming device (566) willdetermine the final shape of the resultant multi-member cable. As wasdiscussed above, the multi-member cable can then be cooled using a watertrough or other device (which now cools the jackets and adheringpoints), and, if desired, a cabler or other helix-forming method canintroduce a twist to the resultant multi-member cable.

In an alternative embodiment, the extrusion die (511) can be replaced bymultiple dies each of which produces a subset of cables that are laterto be co-formed at a singular forming device. In still anotherembodiment, multiple forming devices, crossheads, and/or closing diescould be used in the manufacture of a single multi-member cable bymanufacturing portions of the cable in series and/or in parallel.

While the invention has been disclosed in connection with certainpreferred embodiments, this should not be taken as a limitation to allof the provided details. Modifications and variations of the describedembodiments may be made without departing from the spirit and scope ofthe invention, and other embodiments should be understood to beencompassed in the present disclosure as would be understood by those ofordinary skill in the art.

1-34. (canceled)
 35. A method of installing cable comprising: providinga multi-member cable including at least three component cables havingindividual jackets and bonded by an adhesive element; grasping aterminating end of said multi-member cable; separating one of saidcomponent cables from said adhesive element by breaking said bondwithout damaging said jackets; installing said one of said componentcables; and repeating said steps of separating and installing for theremainder of said at least three component cables
 36. The method ofclaim 35 wherein said adhesive element comprises plastic.
 37. The methodof claim 36 wherein said plastic comprises polyvinyl chloride (PVC). 40.The method of claim 35 wherein at least one of said at least threecomponent cables comprises a voice or data cable.
 41. The method ofclaim 35 wherein at least one of said at least three component cablescomprises a coaxial cable.
 42. The method of claim 35 wherein at leastone of said at least three component cables comprises an optical fibercable.
 43. The method of claim 35 wherein said at least three componentcables are arranged in a non-parallel arrangement.
 44. The method ofclaim 43 wherein said at least three component cables are twistedtogether.
 45. The method of claim 44 wherein said at least threecomponent cables are twisted into a helix.